Embodiment
With reference to Fig. 1 and 2, an embodiment of motor 100 of the present invention is shown in the sectional view, and it comprises the leaf formula rotor 102 that is positioned in the stator 104 with winding 105.Leaf formula rotor 102 consists of the core that is applicable to be contained in the cylinder open that the inner surface by stator 104 limits, so as in cylinder open around the central longitudinal axis A rotary core of core.
Rotor 102 is supported by the central shaft 106 around central longitudinal axis A rotation.In one embodiment, rotor 102 comprises steel (or other materials) core, and it has the two groups of relative grooves 107,108 that are parallel to the shaft extension exhibition.Groove 107,108 is configured to hold magnet 110, for example ferrimagnet separately.Stator 104 is configured to have the winding 105 that is connected to control circuit 116.105 energisings of 116 pairs of windings of control circuit are so that rotor 102 is around central shaft 106 rotations.
Each magnet 110 comprises the ferrimagnet 110 of arc.As visible (for example by the cross section of core, the cross section of in the plane perpendicular to center longitudinal axis A, getting), each magnet 110 comprise inner radial surface 118 (for example towards axle A convex surface) and radially-outer surface 120 (for example away from axis A towards concave surface).Each magnet 110 also comprises between zone line 122 between inner radial surface 118 and the radially-outer surface 120 and inner radial surface 118 and the radially-outer surface two stub areas 124 (seeing Fig. 2) in the relative both sides of zone line 122.In the embodiment shown in Figure 2, zone line 122 is wider than stub area 124 in the radial direction.
In one embodiment, Fig. 1 and 2 rotor are used in the IPM motor, and this motor has the permanent magnet that embeds among the rotor core that is formed by the stack of laminations manufacturing.Each lamination comprises the isolated cut groove 107,108 radially outward from central longitudinal axis A.Lamination is stacked, in order to form rotor core, and magnet 110 is placed in the groove 107,108.
Because the cogging torque (cogging torque) that reduces and more sinusoidal back electromotive force (EMF) usually are provided, and leaf formula rotor 102 of the present invention provides the advantage that surmounts cylindrical rotor.This point partly realizes by outer continuous surface fragment 126, such as the core cross section finding of getting in the plane vertical with central longitudinal axis A.Outer surface profile 126 comprises a plurality of the first outer surface fragments 128,128A, it is limited by the first arc 130, the 130A centered by central longitudinal axis A, and consistent air gap is provided between the interior cylindrical surface (shown in the dotted line 104 among Fig. 2) of the first outer surface fragment 128,128A and stator.Rotor 102 also has a plurality of the second outer surface fragments 132,132A, and it is configured to be provided at the inconsistent air gap that its radial dimension changes, and this air gap is limited by the interior cylindrical surface of the second outer surface fragment 132,132A and stator 104.First and second fragment is adjacency (contiguous).
Each consistent air gap has width of air gap W2, and its whole length along air gap keeps substantially constant (for example along fragment 128,128A).On the contrary, each inconsistent air gap has width of air gap W1, and its length along air gap (for example along fragment 132,132A) changes to width of air gap greater than W2 from width of air gap W2.As shown in Figure 2, the inconsistent width of air gap of the second outer surface fragment 132,132A is from the width of air gap W1 at the middle part of fragment 132,132A (for example reducing) the width of air gap W2 to fragment 128,128A that diminishes gradually.In one embodiment, width of air gap W2 is half (for example W2=W1/2) of width of air gap W1 at the middle part of fragment 132,132A.Therefore, W1 subtracts the constant air gap width W 2 (for example W1-W2=W2) that W2 is substantially equal to the consistent air gap in fragment 128, the 128A.
In one embodiment, can expect that the cylinder open of stator 104 is radially limited to the tooth 150 of inner process by a plurality of (M), tooth has the space width (tooth pitch) of 360 °/M.Each the first outer surface fragment 128 of rotor 102,128A limit the first core section 152, the 152A with the first section angle 154,154A, this angle equals N.P times of space width, and wherein, N is integer, P=4,5 or 6 (for example the first section angle=(360 °/M) * N.P).
For example, for the stator 104 with 36 teeth (M=36), make P=5, N can be 1,2,3 or 4, so N.P can be 1.5,2.5,3.5 or 4.5, the first section angle can be about 15 °, about 25 °, about 35 ° or about 45 ° or larger, but also can expect other section angle.
As another example, four magnet rotors 102 for Fig. 2, the stator with M=36 tooth 104 in conjunction with Fig. 1, P=4,5 or 6, the first section angles 154,154A can be in the scope of about 14 °-16 ° (N=1), about 24 °-26 ° (N=2), about 34 °-36 ° (N=3) or about 44 °-46 ° (N=4).In addition, in the embodiment of Fig. 2, the second outer surface fragment 132 of rotor 102,132A limit the second core section 156 with 90 ° of N.P that deduct space width, second section angle 158 doubly, 156A (the second section angle=90 °-(360 °/M) * N.P)) for example separately.For example, as shown in Figure 2, for the stator with M=36 tooth and P=5, the first section angle 154 is illustrated as about 45 °, and the second section angle 158 is illustrated as about 45 °.In this embodiment, the representative value of W1 can be at about 0.030 inch (0.762mm) in the scope of about 0.042 inch (1.067mm), and the representative value of W2 can be at about 0.015 inch (0.381mm) in the scope of about 0.021 inch (0.533mm).
In order to obtain the performance of hope in the broad velocity interval of firm power, than the rotor that uses neo magnet (for example Nd-Fe-B) or neo and ferrimagnet, provide the more magnetic characteristic of balance by the circumference along rotor 102, provide better scheme such as these rotors presented here and motor configurations.In addition, varying air gap only is provided and is not to provide lower inductance than Lmax/Lmin with leaf formula rotor that the second outer surface fragment 132 that inconsistent air gap (for example changing to the maximum of W1) is provided and 132A have the first outer surface fragment 128 that consistent air gap W2 is provided, 128A in combination as described above, this is more unsatisfactory.In addition, compare with the slot effect of the reduction of leaf formula rotor 102 of the present invention and the harmonic wave of reduction, the cylindrical rotor that does not have the leaf formula causes high slot effect and/or harmonic wave in the back-EMF waveform, and this also is more unsatisfactory.In addition, the rotor with multi-layer magnet is more more expensive than the leaf formula rotor 102 with magnet 110, because a plurality of magnets deal with more expensive in the motor unit process of assembling.
The rotor structure of the embodiment of Fig. 2 uses four (4) individual discrete ferrite arc magnets, its can be at zone line 122 thicker and its be arranged in groove, as proposing here, groove can be optimised to the lower slot effect of foundation, higher inductance than Lmax/Lmin and the magnet strength balance that is used for optimize performance.
Usually, use motor of the present invention to have the back-EMF of basic sine, and the motor of use ferrimagnet well known in the prior art and/or neo magnet have the back-EMF that is rich in harmonic wave.Compare with motor well known in the prior art, use motor of the present invention generally to have lower minimum inductance, maximum induction is generally higher with the ratio of minimum inductance, and this has improved the distribution of reluctance torque.Under high speed, compare with motor well known in the prior art, use motor of the present invention also to produce less noise, because there is less total air cavity in the rotor.
It is comparatively more cheap than motor well known in the prior art to use motor of the present invention generally to manufacture.Because its cost that reduces, the sound noise that reduces, the electric noise that reduces can advantageously be applied to consumer electronic appliance, for example horizontal washing machine, dishwasher and dryer according to motor of the present invention.
In the embodiment of Fig. 3-6, compare comparatively simple alternative by using two (2) discrete ferrimagnets rather than using four (4) magnets to realize with Fig. 1-2.Therefore, the invention provides in the lamination manufacture process comparatively simple internal rotor when slotting.
In one embodiment, the second core section 156 that has the quantity that doubles the first core section 152.For example, shown in Fig. 3-6, there are respectively do for oneself four the first core sections 152 of 25 ° and 32.5 ° eight the second core sections 156 of respectively doing for oneself, are total up to 360 °.
Fig. 3-6 shows motor rotor 102, and it has by not being two the second outer surface fragment 132C, the 132D that the second arc 160C, 160D centered by the central longitudinal axis A of core limit, and these arcs define inconsistent air gap.Especially, each second arc 160C, 160D have respectively the second radius R 2, the second radius Rs 2 centered by a B, C less than the first radius R 1.In one embodiment, difference between the first radius R 1 of the first arc 130 and the second radius R 2 of the second arc 160C, 160D is D1, about 0.087 inch (2.21mm) perhaps arrives (for example approximately 1.91mm arrives about 2.51mm) in about 0.099 inch scope at about 0.075 inch.
For example, shown in Fig. 4-6, it is 25 ° for two magnet rotors, 102, the first section angles 154 of being combined with the stator of the Fig. 1 with M=36 tooth, P=5 and N=2.In addition, in the present embodiment, the second section 156 limits together 90 ° and deducts N.5 doubly angle (for example, the total angle=90-of the second section (360 °/M) * N.5), or 90 °-25 °=65 ° of space width.In this particular instance, the first section angle 154 is 25 °, and each the second section angle 158A, 158B are 32.5 °.In this embodiment, R1=1.521 inch (38.6237mm), R2=1.436 inch (36.4744mm), W1=0.035 inch (0.889mm), W2=0.0175 inch (0.445mm).In addition, the widest air gap may be on a D.Distance between some A and the D is 1.50 inches (38.10mm).In the situation of R1=1.521 inch (38.6237mm), the difference between the air gap of R1 and the air gap of D is, the air gap of D may be than the air gap of R1 large 0.021 inch (0.52mm).
Illustrate especially such as Fig. 4-5, in one embodiment, can expect, the stub area 124 of magnet is positioned at the second core section 156, and the zone line 122 of magnet is positioned at the first core section 152.This configuration is tended to the magnetic line of force of magnetic flux is carried out balance, reduces thus slot effect.In the specific embodiment with two second core sections 156 of Fig. 4-5, the stub area 124 of magnet is arranged in two the second core sections 156.Can expect that also stub area 124 can only be positioned among of the second core section 156, perhaps, as an alternative be that stub area 124 can be positioned among both of first and second core section.In this configuration, the groove 107,108 for magnet is placed as so that W3=0.057 inch (1.45mm) and R3=1.379 inch (35.02mm).
With reference to Fig. 4, each magnet 110 comprises the magnet of arc, and it has the inner radial surface 118 that limited by radius R 4 (for example towards axis A convex surface) and the radially-outer surface 120 that limited by radius R 5<R4 (for example dorsad the concave surface of axis A).Each magnet 110 further comprises between zone line 122 between inner radial surface 118 and the radially-outer surface 120 and inner radial surface 118 and the radially-outer surface 120 two stub areas 124 (seeing Fig. 2) in the opposite side of zone line 122.In the embodiment shown in Figure 2, zone line 122 is wider than stub area 124 in radial direction, so R4 and R5 do not have same central point.In the embodiment shown in fig. 4, zone line 122 has same width with stub area 124 in the radial direction, so R4 and R5 have same central point.In the embodiment shown in fig. 4, can expect R5=1.60 inch (40.55mm), R4=2.14 inch (54.35mm).
In another embodiment, the present invention is a kind of method of making IPM motor 100, and this motor comprises rotor 102 and stator 104, and the method comprises:
Stator 104 with annular opening is provided,
Rotor 102 with core is provided, and core can rotate by the central longitudinal axis A around core in stator openings,
In core, provide from the isolated groove 107 of central longitudinal axis outward radial, 108, and
Magnet 110 is positioned in the groove.
Core is manufactured to has the outer surface profile that seems from the core cross section of getting perpendicular to the plane of central longitudinal axis A.This outer surface profile 126 is manufactured to and comprises: a plurality of the first outer surface fragments 128,128A, 138,138A, its arc 130 bendings to be centered close to central longitudinal axis A are in order to provide consistent air gap between the part of respective teeth 150 of restriction annular stator openings of the first outer surface fragment and stator 104; A plurality of the second outer surface fragments 132,132A, 140,140A, it is configured to provide the inconsistent air gap between the part of respective teeth 150 of restriction annular stator openings of the second outer surface fragment and stator 104.Each consistent air gap is manufactured to has width of air gap W2, and its whole length along air gap remains substantially constant, and each inconsistent air gap is manufactured to has width of air gap W1, and it is along the length variations of air gap.
Can expect, without departing from the invention, can be in many ways in conjunction with the aspect of the embodiment that introduces above.
Above introduction also be applicable to other electromotor structure, inverted motor and/or in rotor, have winding and in stator, have the motor of permanent magnet for example, vice versa.Magnet configurations and air cavity consider to be similar to those in the rotor design of introducing above.
Run through in full, specification is with reference to the IPM motor rotor, but one skilled in the art will appreciate that motor can be configured to generator.
Describe the present invention in detail, will be seen that, in the situation of the scope of the present invention that does not break away from the appended claims restriction, can make multiple modification and modification.
The execution of the method that illustrates here and introduce and to carry out order be not substantial, except as otherwise noted.That is to say that the inventor can expect, unless otherwise defined, the element of the method can be carried out with any order, and the method can comprise with element disclosed herein and compares more or less element.For example, can expect, before another element, simultaneously or carry out afterwards or carry out the scope that specific element belongs to various embodiments of the present invention.
When introducing the element of the present invention or its preferred embodiment, there are one or more element in article " ", " one ", " being somebody's turn to do ", " described " for meaning.Term " comprises ", " comprising ", " having " are used for inclusive, means the additional elements that may exist except institute's column element.
Because upper, will be seen that several purposes of the present invention are accomplished, and obtained other favourable outcome.
Without departing from the scope of the invention, can in the said goods and method, make multiple modification, all themes that comprise in the top specification and shown in the drawings are interpreted as illustrative, are not determinate.